SIPLACE SMT-INSIGHTS

Transcription

1 SIPLACE SMT-INSIGHTS Challenges in the electronics production & SIPLACE solutions

2 Hardware alone is no longer the solution Editorial THE electronics production per se no longer exists. For laypersons all SMT lines may look alike, but experts recognize a wide range of different processes. Old categorizations no longer work. Today a low-volume/ high-mix process may run directly next to a high-volume/low-mix process not just on the same production floor, but on the same line. As electronics become ever more pervasive in our lives, the range of services provided by electronics manufacturers has grown as well. They optimize products under production aspects, control quality, support their customers supply chain processes and function as fulfillment centers. In short: electronics production is becoming ever more diverse and individualized. What are the consequences arising from these developments? The makers of SMT equipment must address this new level of diversity. Standard hardware and placement performance are no longer sufficient. The future belongs to the perfect interaction of hardware, software and services flexible solutions that provide the best available support for individual production processes. As a technology leader, the SIPLACE team has set the standards for hardware, software and services for many years. In matters of individualization and process optimization, SIPLACE developers are working closely with OEMs and EMS providers all over the world. The goal: Providing concrete solutions for individual challenges in core processes such as New Product Introduction, Setup Changeover and Production Run. What are your individual requirements? This Insights brochure describes examples of the way we address our customers challenges by combining our long-term experience with our hardware, software and services. I am confident that you are quite familiar with these challenges. If you have encountered other, more specific problems in your electronics production and want to improve your efficiency, quality and/ or your process reliability, give us a call. We would love to hear from you. With best regards, Günter Lauber 2

3 Providing the best possible support for production processes Previous generations of placement machines did what their name implied: place components no more, no less. The rigid hardware concepts of the past have become obsolete in modern electronics manufacturing with its diverse requirements. However, electronics manufacturers who want to improve their efficiency as well as the quality and speed of their processes can achieve these goals only with flexible, scalable placement platforms. An athlete who can only run very fast will never win the decathlon. In electronics production, virtually every product and every customer represent a new discipline with significantly varying requirements: small or large modules, various components, single-sided and dual-sided placement, materials which must be purchased or are being supplied by the customer, as well as different lot sizes, lead times and quality standards. And everything has to meet the highest standards, of course. SIPLACE engineers recognized earlier than other equipment manufacturers that rigid placement machines are no longer able to meet the demands being placed on increasingly flexible electronics production. What is needed are solutions that can perform in many different disciplines. These requirements brought about modern placement platforms like the SIPLACE SX, which is able to adapt to a wide range of tasks with modular hardware, intelligent software and customized service offerings. Many electronics manufacturers are still struggling with challenges for which SIPLACE already has the answers. The SIPLACE Challenge Cup will demonstrate how far we are ahead of the competition. With optimally coordinated combinations of hardware, software and service modules, SIPLACE offers electronics manufacturers the advances in flexibility, speed and efficiency they need across the entire production cycle. Gabriela Reckewerth, Head of SIPLACE Global Marketing 3

4 Perfect for fast changeovers: the SIPLACE MultiStar CPP alternates between the different placement modes. SIPLACE SX: the very latest and most flexible placement platform for any modern electronics production. Lowering process costs The latest SIPLACE innovations focus on reducing your process costs. New SMT lines require significant investments. Studies also show that the costs of suboptimal production processes accumulate to significant amounts over time. For example: When lot sizes get smaller and the frequency of product changeovers is on the rise, setup-related line stops have an increasingly negative effect on line productivity. The innovative setup strategies possible with SIPLACE platforms allow you to accelerate your product changeovers or even eliminate line stops altogether. As a result, you save money on every setup changeover. In flexible production environments, these savings can quickly accumulate to many times the machine investment. Manufacturers who want to lower their costs and become more competitive over the long term must increasingly pay attention to their processes and to the ways in which their placement platforms and technology partners support these objectives. Wellcoordinated hardware, software and service modules provide additional speed and efficiency for frequently executed processes. They may even make it possible to completely reorganize and improve your processes. Keeping an eye on the entire process It may sound contradictory, but a chain of optimized subprocesses does not produce a process that is optimized in its totality. That s why process experts stress the need to always keep an eye on the overall process. For example, some equipment makers focus on a variety of placement head versions in order to optimize the performance of their lines for specific component spectrums. While this reduces the placement times per The acquisition of SIPLACE by ASMPT was an excellent move for both parties. I am confident that the future will be just as successful and inspiring as the past nine months have been. As far as I am concerned, there is no better team in the industry than ASM AS. Sven Buchholz, SIPLACE Cluster Head Central Eastern Europe 4

5 Placement platforms, placement heads, transport systems, feeders and software: With tailored solutions, SIPLACE supports process optimization for example seamless changeovers. product, it also requires more configuration effort when products change, as well as more capital investment for the large number of specialized heads. SIPLACE engineers, on the other hand, focused on the total process, i.e. the entire order mix. They determined that for production environments with frequent product changeovers a highly flexible placement head with no need for head changes and the resulting downtimes is the more efficient solution overall. The result was the development of the unique SIPLACE MultiStar placement head, which can change placement modes for each cycle based on software commands, enabling it to place small standard components and large shapes with equal efficiency. Customers tell us what they need Flexibility, modularity, software, service and optimized processes why have SIPLACE placement platforms set industry standards in these areas for so many years? Because we made our customers our most important source of information and innovation. Unlike many of our competitors, the SIPLACE team with its global cluster organization is on-site at customers all over the world. Our developers hear about what our customers need quickly and directly from the source. New Product Introduction (NPI), Product Changeover and Setup Strategies and Production Run have emerged as the core processes in modern electronics production environments. To answer the challenges in these areas, the SIPLACE team has created many superior solutions in recent years by combining hardware, software and service modules in innovative ways. This brochure tells you more about these solutions. As part of ASMPT, SIPLACE really values its people. This culture of being there for each other and looking out for each other is the basis of SIPLACE s success. Jack Chua, SIPLACE Cluster Head South East Asia 5

6 The SIPLACE SX is the first placement platform offering Capacity-on-Demand functionality and enables the electronics manufacturer to be flexible and adapt to sudden fluctuations in demand. SIPLACE solutions: The perfect combination of hardware, software and services With frequent product changes, high quality requirements and extremely dynamic order situations, electronics manufacturers must be able to operate with exceptional flexibility. Equipment makers who focus exclusively on hardware are no longer able to provide sufficient support for these requirements. That s why SIPLACE engineers embarked in a different direction many years ago: They had the groundbreaking idea of the modular placement platforms which can be combined with hardware, software and service options to provide electronics manufacturers with customized solutions for their individual processes and requirements. As a result, the SIPLACE SX placement platform is the current industry standard against which all others are measured. The areas for which users employ the SIPLACE SX range from prototype production with standalone machines to high-mix lines at EMS providers to IT/telecom applications to medical and automotive applications and even to LED placement. How can a single placement platform perform in such a broad spectrum of applications and deliver so much flexibility? Let s look at some examples: Intelligent heads and smart feeders Hardware-centered equipment makers believe that a wide spectrum of specialized The SIPLACE SX with its Capacity-on-Demand concept is exactly the right machine at the right time for our markets in the Americas. There is currently no better machine on the market. Mark Ogden, SIPLACE Marketing Americas 6

7 Collect&Place, Pick&Place, Mixed Mode: Via Software the SIPLACE MultiStar CPP can cope with any task. Experts: The SIPLACE Service Technicians will help you optimize your individual processes. placement heads is the way to go. They may deliver high placement speeds, but are inflexible when products must be changed and must be frequently reconfigured or even replaced. Modern SIPLACE placement platforms on the other hand make do with only three head models. While the SIPLACE CP20 SpeedStar handles the fast placement of standard components, the highly accurate SIPLACE TwinHead places large components, connectors and odd shapes at the end of the line. The flexible link between these two is the unique SIPLACE MultiStar CPP. It is the world s first placement head that is able to switch between Collect & Place, Pick & Place and Mixed modes in response to software commands. This provides electronics manufacturers with huge flexibility: Instead of wasting time by switching out placement heads, they can let the software do the work with a single SIPLACE MultiStar. With the MultiStar, they can use the same head to place 01005/0201 components, LEDs and odd shapes. The perfect complement to the SIPLACE MultiStar are the intelligent SIPLACE X- feeders. They operate with exceptional precision while supporting the large number of innovative SIPLACE setup concepts. Thanks to their wireless data and power transmission, X-feeders can be switched out without having to stop the machine. Thanks to their feeder IDs, the placement Korean electronics manufacturers place great value on being one step ahead when it comes to translating technological innovations. One such example is the placement technology for automotive components. SIPLACE was one of the first to offer the perfect solution including highest quality control and enlarged specifications for large unit volumes with its SIPLACE SX. Rest assured, together with our customers we are already working on the next market-leading solutions. DS Kim, Head of SIPLACE Korea 7

8 According to demand, placement performance is scalable and transferable: Within minutes the unique SX gantry can be either installed, or de-installed. Paperless: SIPLACE Solutions for material management and changeover processes platform recognizes which feeder is mounted where and adjusts the placement program accordingly. And their built-in LEDs let operators know when they can be installed and de-installed. Modular gantry concept creates a capacity-on-demand platform In the past, changing the performance of SMT lines required expensive line reconfigurations and long production shutdowns. The superior concept of the SIPLACE SX: gantries, which can be installed and uninstalled in just a few minutes. That way, you can quickly turn a SIPLACE SX1 into an SX2 with twice the speed, but without having to change the line configuration or add to its footprint. The SIPLACE software recognizes the change, adjusts the placement programs and puts the additional performance to use right away. The perfect addition: Rental services The ability to add and remove gantries provides true scalability in the technical sense. Classic purchase models, however, have financial disadvantages since the gantries have to be bought, thus tying up capital and increasing fixed assets. SIPLACE on the other hand enhances the technical capabilities of the modular gantries with its unique rent-a-gantry services: Electronics Our machines have advanced into placement platforms to meet the needs of modern electronics production. The development of software and service concepts is at least as important as progress we are making in hardware. Overly rigid solutions can bring manufacturers to their knees almost overnight not only in Europe. That s why we have been thinking in terms of process requirements for a long time now. 8 Bernhard Fritz, Head of SIPLACE Product Marketing

9 SIPLACE Service offers more than technical training: Process consulting, certification, leasing and hire services. SIPLACE Vision Teaching Station: Efficient offline teaching relieves the production lines. manufacturers simply rent any additional gantries they need at short notice and return them when they are no longer needed. This is an easy and liquidity-preserving way to respond to fluctuating order situations. SIPLACE is therefore the first equipment manufacturer who supports breathing, order-oriented electronics production ( capacity on demand ) with its placement solutions. Conclusion: Optimizing your processes requires hardware, software and services Whether the focus is on line software, setup verification, detailed scheduling or setup concepts the huge bandwidth of SIPLACE software makes it possible to adapt the placement platform to each electronics manufacturer s individual processes. And once this has been done, SIPLACE services provide the finishing touch ranging from maintenance concepts with defined service levels, training, certification and capability transfers to leasing or rental services that improve your liquidity and financial stability. Today, investment decisions are no longer made simply based on the hardware s theoretical maximum speed, but on what the solution actually delivers for your concrete order mix and in your individual production environment. That s why SIPLACE is always the smart choice. Our integration into ASMPT has now been finalized in China as well. The mood is excellent you can truly call it a new spirit of optimism. The Chinese team participates in our global organization with creative ideas, and we are confident that together we will satisfy our local customers desire for German engineering in an organization that thinks in Chinese terms. Herbert Hofmann, COO SIPLACE China 9

10 SIPLACE SX is the benchmark for flexible electronics production. The right set up concept can reduce new investment in equipment by 30 percent. New Product Introduction: Introducing efficiently and error-free New product introductions tended to be a special process in the past. In modern production plants, their number is rising rapidly, and NPI processes play an increasingly important role for efficiency and productivity. SIPLACE is the first equipment maker who has defined the NPI process as a central, frequently recurring workflow in modern electronics production. The result is a comprehensive spectrum of hardware, software and service tools with which SIPLACE seamlessly supports today s NPI processes. The NPI process can be subdivided into three phases: Phase 1: Data transfer and product description Phase 2: Placement program verification via virtual placement Phase 3: Efficient initial placement with program completion/optimization SIPLACE placement solutions offer special tools for each of these phases. For example, new components can be described offline or directly on the machine in seconds, and placement programs can be executed virtually on the computer (without run-ins or adhesive foils). The tools and the entire NPI process are designed for maximum error tolerance. If the NPI process poses practical challenges for you, SIPLACE has the solutions. Whether you need to import incomplete or faulty production data, teach unknown components, set up the line for prototypes and small lots, handle second-source components or handle placement sequence interdependencies (shields, shadows), SIPLACE can help you handle it. A structured and tool-supported NPI process can significantly reduce line downtimes as well as the costs associated with new product introductions in terms of both time and money. At the same time, your place- The global SIPLACE Team is on the right track: we have considerably increased our market position world-wide, but especially so in Asia. Our target is and will remain to be: Together #1! Ray Bruce, Head of SIPLACE Global CRM 10

11 SIPLACE feeder options provide efficient placement also for exotic components. NPI, changeover strategies and production processes: SIPLACE optimizes customer specific processes. ment programs become better, with positive results regarding both first-pass yields and customer satisfaction. You become more competitive by gaining the ability to run new products quickly, efficiently and reliably with state-of-the-art programs and processes. SIPLACE tools for NPI processes SIPLACE Pro SIPLACE Vision Teaching Station SIPLACE Gerber Data Import SIPLACE Component Libraries SIPLACE Special Nozzle Services SIPLACE LED Pairing SIPLACE Precedence Finder SIPLACE Setup Concepts Professional programming including PCB Scan, Virtual Product Build and SIPLACE Optimizer Describe components at the machine or offline at the SIPLACE Vision Teaching Station Gerber Data Import for board description Quick access to component library data, including information about feeders and nozzles Development and production of nozzles and grippers for odd shapes and unusual components Automatically pick the matching resistor for each LED brightness class Optimize the right placement sequence based on precedence rules The right placement concept for each production environment SIPLACE Capability Transfer Tools and expertise for your in-house teams The topic Innovative Set-up Concepts is becoming more and more important in Asia. SIPLACE is the only one who can offer a comprehensive solution consisting of hardware, software and services. Irene Lim, SIPLACE Marketing South East Asia 11

12 New Product Introduction: Challenges and SIPLACE solutions SIPLACE tools for NPI process optimization can be combined into customized solutions based on the customer s requirements. Below are some typical examples of NPI process challenges which electronics manufacturers presented to us. In response to these requests, SIPLACE experts developed or configured and set up the appropriate solution. Teaching odd shapes offline on the SIPLACE Vision Teaching Station Can the SIPLACE team program the new component offline in two minutes or less? Bernhard Rindt, Member of the Management Board SRI Radio Systems GmbH, Durach, Germany Mr. Rindt, what do you do if you have to introduce a new product but your or SIPLACE s library is missing one of the components? Bernhard Rindt, Member of Executive Management: We would have to spend a lot of time programming such a component, which is something we would like to avoid. With the external SIPLACE Vision Teaching Station, new components can be measured and described offline, i.e. without interfering with the running production. If the component is an unusual or odd shape, these descriptions can then be transmitted to SIPLACE. SIPLACE s experts will then recommend appropriate nozzles. If necessary, SIPLACE will also develop and produce customer-specific nozzles. SIPLACE also offers you to lease the SIPLACE Vision Teaching Station instead of buying it to protect your budget, including employee training (SIPLACE Capability Transfer). With our state-of-the-art SIPLACE factory in Munich, our production site in Singapore and our consistent focus on creating value we have the capability to meet our customers needs for high-quality products quickly and individually. Jörg Cwojdzinski, Head of SIPLACE Supply Chain Management 12

13 Teaching components at the SIPLACE machine Matthäus Sigl, Production Manager SMT BMK Group, Augsburg, Germany Quick and flexible introductions of new products are something we deal with every day. Since we run up to 20 new products on our lines each week, receiving a component only at the last minute is nothing unusual. In such cases, every second counts, and the component must be described, set up and installed on the machine as quickly as possible. Can the SIPLACE team describe the new component in two minutes or less? If certain components for a product are not described, electronics manufacturers are unable to download these incomplete placement programs to the line. Valuable time is often lost if the missing components arrive late. The standard version of SIPLACE Pro now includes a new feature that allows the user to mark certain components as incomplete when programming the board on the line computer. The program is otherwise complete and can even be downloaded to the line. When it is time to run the first board, the SIPLACE machine reminds the operator that one or more components are marked as incomplete and requests him or her to teach the component(s) directly at the machine. With the help of software wizards and the component camera, this can be accomplished in just a few seconds, and the data is transferred instantly to the placement program, which is now complete. The placement run can start immediately thereafter, and the first board is fully processed. For Japanese electronics manufacturers, getting the best technological and financial solution from a reliable partnership really matters.siplace s highly flexible solutions are best for their need, which is why I, as a Japanese person, am very happy to be part of this global team. More and more of my Japanese customers around the world obviously agree. Katsuya, MIURA, SIPLACE Japanese Account Manager 13

14 Gluing heavy components with the SIPLACE Glue Feeder is mounted on the machine like any other X-feeder module. The benefit: Instead of applying glue to the board, the SIPLACE Glue Feeder applies adhesive to the component in a precise location during the placement process. Another advantage: Since the SIPLACE Glue Feeder turns any machine into a glue station, electronics manufacturers gain additional freedom in assigning production jobs and utilizing their lines. BMK and Pepperl+Fuchs are also delighted about the solution for this challenge. Matthew Goeringer, VP of Manufacturing Arc-Tronics, Inc., Elk Grove Village, USA I am a contract manufacturer, and I just received an order to produce dual-sided boards. Since a heavy component on top of the board falls off when the board runs through the oven the second time, I have to glue it. A new glue station is a major investment, and with many equipment makers it requires me to sacrifice an entire placement module. Matthäus Sigl, Production Manager SMT BMK Group, Augsburg, Germany Can the SIPLACE team apply glue to a component during the placement process with no placement head modification? The SIPLACE Glue Feeder converts the SIPLACE placement platform into a costeffective glue station without reducing its performance. The SIPLACE Glue Feeder Yap Seng Thong, Manufacturing Manager Pepperl+Fuchs Pte Ltd, Singapore Both the ASMPT and the SIPLACE teams worked together very quickly. Especially with regard to future product developments we can still learn a lot from each other. Our competencies are similar, but we operate in different markets. Günter Schindler, SIPLACE COO 14

15 Optimizing the component shape description with the SIPLACE Vision Test Suite shape description would produce. The necessary images can come from the machine as vision dumps or be taken offline at the SIPLACE Vision Teaching Station. Only one component sample is needed. The SIPLACE Vision Test Suite can be purchased or leased as part of our Capability Transfer services. Bernhard Rindt, Member of the Management Board SRI Radio Systems GmbH, Durach, Germany When we have to place a new component, we sometimes encounter problems which can be traced back to the quality of the component shape description. Adjusting the component shape and running a test on the line with the actual product is not possible for cost and time reasons. Can the SIPLACE team verify the modified component shape within ten seconds or less? Using images of a component, the SIPLACE Vision Test Suite makes it possible to execute a full simulation within only a few seconds. The system indicates quickly and reliably which quality improvements a better component An important part of the SIPLACE Vision Teaching Station is the SIPLACE Vision Suite. In Asia, speed wins. Together with the renowned European thoroughness, the high SIPLACE quality standards and the ASMPT resources, we are able to offer unbeatable placement solutions. Jing Guan, SIPLACE Marketing China 15

16 Determining the best placement sequence with the SIPLACE Precedence Finder With the SIPLACE Precedence Finder, determining the safest and most efficient placement sequence is easy. The software recognizes any shadowing of large components and interdependencies in the placement sequence (shields, PoPs, etc.). It warns the programmer and proposes changes. It even takes the geometries of special nozzles into account. Willi Keckstein, Project Manager Gigaset Communications GmbH, Bocholt, Germany Mr. Keckstein, we repeatedly hear from our customers that processing modules with high component densities is pretty complex. What can the SIPLACE team do to make this process easier? Assigning the proper resistors to LEDs with LED Pairing Let me give you an example: We have here a complex electronics module with tall components located directly adjacent to low ones. We also have a high component density, and finally we have to place a shield at the end. For this PCB we would like to generate an intelligent and robust placement sequence that avoids collisions and places components in a logical order. Can the SIPLACE team determine in 30 seconds or less a placement sequence that avoids any head collisions? Peter Eiting, Production Planner, SIPLACE ASM Assembly Systems, Munich, Germany My dashboard PCB contains several LEDs. As is always the case with LEDs, the resistors must match the brightness class. How can I make sure that the system always places the right combination of resistors in accordance with each LED s brightness class? SIPLACE placement solutions provide the matching concept for any conceivable production requirement. The SIPLACE SMT Insights issue titled Progressive Setup Concepts for Modern Electronics Production tells you more about these and explains for which requirements they were designed. Ask for your own copy. 16 Thomas Hüttl, SIPLACE Product Marketing

17 Programming with nothing but Gerber data in SIPLACE Pro Can the SIPLACE team set up a specific placement program with only the Gerber data available? Lin Xinyong, SMT Supervisor Konka Electronics Co., Ltd., Dongguan, China I have only Gerber data and a prototype PCB for my new product. Unfortunately I have no placement positions whatsoever. Generating the placement program would take me hours. Even the standard version of the SIPLACE Pro software is able to import Gerber data in various formats. In addition, the PCB can be scanned in (with or without components). Once this has been done, everything goes very quickly: You drag and drop the components to the PCB. Once this has been done, you verify the results in SIPLACE Virtual Product Build via a virtual placement and make any necessary corrections (angle, offset, etc.). As a result, you can run the first board through the line error-free after only a few minutes. Can the SIPLACE team combine each LED with the correct resistor? With SIPLACE LED Pairing, the SIPLACE experts have created a lean solution for specifying LEDs and their associated resistors in placement programs. Once the LED-resistors combinations have been entered in the form of a simple list, the system automatically selects the right resistors when the LED reels are scanned in SIPLACE Setup Center and enters them in the placement program. That way, neither the programmer nor the operator can make any mistakes. Of course, our customers contact us when they need us to overhaul their machines, maintain them or simply help with application problems. Over time the focus has clearly shifted, however. We are increasingly being asked to get a handle on our customers requirements and advise them before they purchase equipment. Thanks to our modular service structure we have lots of tools at our disposal to make sure that production problems don t happen in the first place. Phil Read, Head of SIPLACE Service UK 17

18 Seamless setup where there is space available: SIPLACE Random Setup. De-instal? The LEDs on the SIPLACE X-Feeder help with the changeover. Setup Changeover: The fitting concept for each production environment The second process that is critical for the success of an electronics plant involves the variety of products to be manufactured and the related effort required to execute product changeovers on the placement line. The flexi bility spectrum ranges from million-unit runs with a single changeover per quarter to multiple changeovers per shift with lots sizes in the single digits and a planning horizon of only a few hours. That s why it is so important for today s electronics manu facturers to take the available setup concepts into account when they plan to invest in new equipment. Just like with placement machines, finding the right placement concept involves selecting the solution that delivers the greatest efficiency with regard to productivity and investment under the specific conditions. That s why it pays off to be open to new solutions approaches, because by smartly combining software and placement solutions you can implement setup changeover concepts today that used to be nothing but wishful thinking yesterday. In view of the many options available, selecting a suitable setup changeover concept can become a challenge in itself, particularly since the future product mix might change. On the other hand, selecting the optimal setup concept can reduce the cost of feeders and entire placement modules by up to 30 percent and make a significant dent in the placement costs during regular production when a manufacturer invests in new lines. That s why it is so important to confront each equipment supplier with all your challenges regarding setup requirements and to pick the one who offers the largest and most advanced portfolio of setup concepts. In R&D as well as in all other SIPLACE departments, German engineering and the innovative creativity with which we deliver the right answers to our customers challenges are part of our brand. Robert Steiner, SIPLACE R&D 18

19 High Quantity Fixed Single Setup Family setup with static/dynamic changeover table concept Floating Setup SIPLACE set-up concepts Low Product High As a rule, this means: Groundbreaking placement solutions provide the matching concept for any conceivable production requirements. The most efficient solutions are those where placement equipment and software concepts complement each other perfectly. SIPLACE tools for optimal placement concepts SIPLACE X-Feeders SIPLACE Conveyors SIPLACE MultiStar SIPLACE Feeder Table SIPLACE Preparation Tables SIPLACE Setup Center SIPLACE Pro SIPLACE Random Setup SIPLACE Split Table Mode SIPLACE Constant Tables SIPLACE Stationwise Download SIPLACE LES Intelligent, versatile, with unique feeder ID and direct data communication From single-lane to quad-lane transports The all-round talent for components ranging from to 50 x 50 mm Offline setup preparation and verification Movable feeder tables for maximum setup flexibility For setup verification in the preparation area and on the line For top-of-the-line programming (see NPI) Floating setup changeover with free choice of feeder position per feeder table or alternatively per line For floating setup changeovers Fixed setup of reels used for multiple products reduces the setup effort Product changeovers without having to clear the line Setup scheduling and optimization for high-mix production environments with free choice of feeder positions (per feeder table) I am very proud of the SIPLACE Team. None of our competitors is as well equipped, as fast and as innovative with so many technological capabilities Especially in China will we be able to win more new customers with these unique solutions. Joe Poh, SIPLACE Cluster Head China 19

20 Setup changeover: Challenges and SIPLACE solutions In the eternal search for more efficiency, minimizing setup-related production interruptions is one of the greatest challenges today. On these pages we present current examples from various electronics manufacturers along with corresponding process improvement proposals from SIPLACE. Material transparency on the production floor with SIPLACE Facts Reiner Thiele, Production Engineering Siemens Elektronikwerk, Amberg, Germany One of our goals at Elektronikwerk Amberg is to achieve maximum material transparency in our production. We repeatedly encounter discrepancies between our theoretical and actual inventory numbers, which can easily lead to production stops. We would like to have a solution that lets us locate material in the shortest possible time. Does the SIPLACE team achieve maximum material transparency? SIPLACE Facts is an order and materials management solution that was designed especially for the requirements in electronics production. It seamlessly links the ERP system with the production floor and handles material flows from receiving to line placement as well as returns to the component stock. Stock and consumption data for components and reels as well as their locations in warehouses or on production lines are fully transparent at all times. It also takes storage strategies (FIFO, etc.) and exposure times of MSDs into account. Employees receive the information they need as well as pick lists and BOMs electronically via PDAs. Component and/or reel IDs are recorded via scanning. Yes, our German customers initially had some reservations regarding the new situation. Today, however, they say that the SIPLACE team has once more reinvented itself while sticking to the same basic values of technological leadership, reliability and constancy. In short: We can depend on SIPLACE and its German engineering. 20 Ralf Blömer, SIPLACE Cluster Head Germany

21 Floating setup changeovers with SIPLACE Random Setup Matthew Goeringer, VP of Manufacturing Arc-Tronics, Inc., Elk Grove Village, USA To speed up our setup changeovers, we are already operating with movable feeder tables and offline setup stations. Are there any other concepts which would make our setup processes even faster and more flexible without having to invest in additional hardware? Can the SIPLACE team set up product B while product A is still running without having to stop the line? The innovative SIPLACE Random Setup concept is the right solution for this customer. With SIPLACE Random Setup, the new product is loaded into SIPLACE Pro while the previous product is still running on the line. Random Setup now determines any differences and indicates which feeders need to be removed and which components have to be set up and added. The new feeders are then prepared away from the active line at the docking station, and the component IDs and feeder IDs are associated with each other (a process called kitting ). Next, the operators take the new feeders to the line without a feeder table. They then place the feeders in empty slots or replace feeders whose LEDs indicate that they will not be needed in one of the upcoming setups. When the production of the new product starts, the SIPLACE machines recognize the positions of the X-feeders and the components they hold based on their IDs, adjust their placement program accordingly and start populating the new boards without a line stop instead of having to exchange complete tables, which frequently involves removing and adding the same components. Random Setup requires only the addition or replacement of individual feeders. The result: With SIPLACE Random Setup you can implement highly-efficient, non-stop setup changeovers. You benefit from speedier setups and fewer stock movements while reducing the number of feeders and changeover tables you need. The SIPLACE SX was like a thunderbolt in my region of South West Europe. Small, flexible, very robust and modular, and above all at a very attractive price the perfect machine for a market which ranges from very small electronics manufacturers to large global players. Thierry Charlot, SIPLACE Cluster Head South West Europe 21

22 Clever board stabilization with SIPLACE Smart Pin Support of the support as part of the placement program in SIPLACE Pro. The software warns the operator if the selected pin position will collide with components on the bottom side of the board. Based on the placement program, the pin placement unit on the placement platform takes support pins from the magazine and places them in their predefined positions. The camera and a fan on the unit prevent discards on the conveyor from interfering with accurate support pin placement. Dieter Mussemann, Production Engineering Siemens Elektronikwerk, Amberg, Germany In our flexible production environment with lots of fast setup changeovers I must also deal with board support pins and make sure that no support pins hit any components on the bottom side of the PCB. We are currently doing this manually, but this is inaccurate and time-consuming. We also would much rather use the resulting downtime to produce more boards. Transparent feeder condition and location data with the SIPLACE Feeder Manager Can the SIPLACE team set the pins automatically in five seconds or less without hitting a component on the populated bottom of the PCB? With SIPLACE Smart Pin Support, the cumbersome and error-prone manual placement of support pins becomes a thing of the past. You simply define the position Bernhard Rindt, Member of the Management Board SRI Radio Systems GmbH, Durach, Germany Whenever I run a new product I don t know if I have enough feeders in good condition and where they are located. SIPLACE SX, SIPLACE set-up concepts, so many larger and smaller innovations presently it s a real pleasure and very satisfying to sit together with customers and determine the most perfect and successful production solutions. Goeran Mellgren, SIPLACE Cluster Head North West Europe 22

23 Saving on investment by defining constant feeder tables with SiCluster Pro Reiner Thiele, Production Engineering Siemens Elektronikwerk, Amberg, Germany Can the SIPLACE team have the required feeder on the line in 30 seconds or less? Properly working feeders are a prerequisite for an accurate and trouble-free placement process. In larger production environments, you will soon lose control of your feeders without a systematic feeder management system. The SIPLACE Feeder Manager is a professional monitoring tool for all your feeders. You can define any storage location (racks, lines, setup preparation areas, maintenance, outside repair facilities, etc.) and have access to each feeder s entire maintenance history at all times. Based on this information you can control your inventory, govern deployments, perform proactive maintenance or identify trouble-prone feeders. We have analyzed various setup concepts for quite some time now. When we change setups, we usually replace all feeder tables. When we took a closer look at our products, we noticed that we use some components for several products. We already tried to determine these multi-product components manually and set them up permanently in order to reduce our setup effort. Unfortunately, this slowed down our cycle times considerably. We would like to save on setup equipment and labor in this area. Can the SIPLACE team reduce our investment in additional setup equipment by up to 50 percent without creating a significant increase in the cycle time? The setup optimization in SiCluster Pro reliably recognizes components which are repeatedly being used for different products. This information can be used to set up the corresponding components on one or two selected feeder tables. The setups then take these tables into account as constant tables which remain on the line and don t get switched out with each setup change. The benefit of this approach is not limited to a simpler and faster setup process. Since some tables and feeders remain on the line permanently, you need significantly fewer of them, which leads to lower investment and maintenance costs. With product innovations such as the SIPLACE SX and the commitment of ASM from an investment perspective, ASM Assembly Systems has gained a brilliant strategic position in all of our core markets. Jeff Timms, SIPLACE Cluster Head Americas 23

24 Our target is to provide competitive advantages for our customers. SIPLACE Engineering Data Manager (EDM) provides structure and transparency for the production data. Production Run: Exploiting efficiency reserves New components, minor placement program changes, operator errors electronics manufacturers face lots of challenges, also during regular production runs. Whether the focus is on materials, equipment or people, there is lots of potential for improvements not only with regard to setup processes and new product introductions, but also with regard to processes around simple SMT production runs. These challenges, which exist in many production processes, can be resolved by intelligently combining hardware, software and services. Determining and implementing process improvements becomes a lot easier if they are supported by software and modules for your specific placement platforms. A particular important factor for production runs is the minimization of malfunctions and production interruptions. Their causes frequently lie in upstream processes, however, such as in the material supply activities, the inferior quality of components or insufficient equipment maintenance. Problems in these areas can be resolved with the appropriate tools. Other causes can be technical defects or operator errors. This is where the focus is on the user. To keep the placement process running, he must have complete control over machines, material supplies and production jobs. The goal is to put all of the placement platform s capabilities to good use in order to have a robust production process that is protected against all kinds of trouble. Another optimization target is the machines themselves, because they operate most efficiently when they run non-stop. At the same time, many producers face the challenge of having to ensure not only the traceability of components, but to document consistent placement quality with machine capability analyses. All of these requirements can be met a lot more easily today. In my opinion, SIPLACE is the only equipment supplier who has all the resources in the areas of NPI, Setup Changeover and Production Run with highly flexible placement solutions, powerful software tools, state-of-the-art setup concepts for any requirements and many tools that deliver ease of use, transparency and non-stop production. 24 Hubert Egger, SIPLACE Product Marketing

25 Process confidence: SIPLACE Vision System recognizes in a few milliseconds any defect or faulty components. Very user friendly: SIPLACE Smart GUI supports the user with visual aids. It therefore pays off for electronics manufacturers to pay close attention to their equipment suppliers tools in the areas of man, machine and materials. By smartly combining hardware, software and service modules, electronics manufacturers can make their processes more robust and increase the speed and quality of their production runs. SIPLACE tools for production run processes SIPLACE SX SIPLACE Alternative Components The scalable capacity-on-demand solution with innovative exchangeable gantries For defining alternative components in the placement program SIPLACE Nozzle ID Scanning SIPLACE Auto Recovery SIPLACE Smart GUI For automatically selecting the right nozzle Continues the production process after a power failure without missing a beat Friendly user interface with visual troubleshooting instructions SIPLACE Performance Monitoring SIPLACE Alternative Track SIPLACE Facts Material Management SIPLACE Traceability Gives you direct access to production-relevant information Lets you set up multiple instances of identical components to minimize reels running out Materials management solution for electronics manufacturers Keeps track of placed components The SIPLACE service team is present with its own people at customers all over the world. With our global cluster organization we are also perfectly networked. Developers as well as service technicians receive information about our customer s challenges directly from the source. In response we have developed a highly modular service portfolio that has no equal in the industry. Jim Leather, SIPLACE Service Product Management 25

26 Production Run: Challenges and SIPLACE solutions The differences in terms of products and applications are extreme. Accordingly, there is huge diversity in production run processes. The following examples show that SIPLACE offers solutions for regular as well as highly specific challenges. Only the training you need: SIPLACE Modular Training this is too long for us. We therefore expect SIPLACE to adapt to our employees level of expertise and shorten their training courses accordingly. Can SIPLACE shorten the training for our employees by 50 percent? Ulrich Niklas, Chief Technology Officer Zollner Elektronik AG, Zandt, Germany Mr. Niklas, you purchased several new SIPLACE placement lines in recent years. That is correct, but we still need the appropriate training for our skilled employees. We found out that this training would take 12 days. Since our employees already have a fair amount of experience, We know from experience that the need for training can vary considerably. Instead of requiring strict training schedules, SIPLACE offers training modules that are structured according to clearly specified focus areas and spread over a certain period of time. That way, electronics manufacturers can train their people in a targeted and needsoriented manner. Analyses conducted by the SIPLACE team show that this concept reduces the training costs and time requirements considerably without com promising its success. As a member of the works council, I was somewhat sceptical initially regarding the SIPLACE team s merger with ASMPT. But after one year of close cooperation I can state that our teams have grown together and that many of our processes are getting easier and more practice-oriented. I am confident that with lots of work and by changing the way we think in many areas we will ultimately achieve our goal of becoming Together #1. 26 Andreas Hofer, Head of SIPLACE Works Council

27 Doubling your placement performance with the capacity-on-demand gantry the SX gantries, which can be installed or de-installed in just a few minutes. This lets you increase or decrease the performance of a line without having to reconfigure it or change its floor space requirements. And since SX gantries can also be rented from SIPLACE for short periods of time, electronics manufacturers can increase and again decrease their capacity at short notice. This provides them with additional liquidity, because they don t have to invest in equipment that is unused for long periods of time. Dr. Matthäus Sigl, Head of SMT Production BMK Group, Augsburg, Germany Dr. Sigl, how do you react to fluctuating order volumes? In short: The SIPLACE SX with its capacity-on-demand capabilities is the first placement platform for a breathing electronics production. This is something we constantly have to struggle with: When our order volume goes up, our customers expect a flexible solution yesterday. We cannot afford to delay our customers until we have set up a new placement line. That s why we want SIPLACE to help us find a solution. Gigaset is also delighted about the solution for this challenge. Can the SIPLACE team double the performance of a SIPLACE SX without having to reconfigure the line? The SIPLACE SX is the only placement platform on the market that was designed for flexible performance adjustment capabilities. SIPLACE achieves this with Willi Keckstein, Project Manager Gigaset Communications GmbH, Bocholt, Germany The SIPLACE SX is the ideal machine platform also for my Taiwanese customers, who have the highest demands with regard to technology, innovation and speed. The SIPLACE SX4 is the perfect addition the right solution at the right time. Excellent. YJ Lee, SIPLACE Taiwanese Account Manager 27

28 Keeping a constant eye on your production with the SIPLACE Performance Monitor order to take corrective action as quickly as possible when something goes wrong. It provides general performance indicators based on the red-yellow-green principle as well as detailed views. Setting up components twice and reducing the need for splicing with SIPLACE Alternative Track Ulrich Niklas, Chief Technology Officer Zollner Elektronik AG, Zandt, Germany How is your production running, Mr. Niklas? Very well right now. At the moment, however, we are running a new job that is very complex and requires my presence on the factory floor. Unfortunately, today is also my daughter s birthday, which means that I have to be at home on time later on. Can the SIPLACE team help us to monitor our production in real time? To meet requests like this one or allow managers at headquarters check production data when the plant is located somewhere else, SIPLACE has developed the SIPLACE Performance Monitor. It enables you to monitor the production remotely in Dr. Matthäus Sigl, Head of SMT Production BMK Group, Augsburg, Germany Regular production runs require lots of splicing. If the reels are small, it may even happen that the line operator cannot keep up, and the machine stops. For cases like these it would be nice to be able to set up components twice on the machine. Can the SIPLACE team set up a component twice without requiring another program download? Although we are now part of ASMPT, we kept our proven organizational structure with our SIPLACE headquarters in Munich and our seven regional clusters. This global cluster organization provides us in all areas with the level of flexibility and agility a global technology partner must offer its customers today. 28 Ralph Pötter, Head of SIPLACE Global Sales

29 No discarded PCBs after a power outage thanks to SIPLACE Auto Recovery Yap Seng Thong, Manufacturing Manager Pepperl+Fuchs Pte Ltd, Singapore We often experience power shortages requiring us to completely clear the line and discard all partially processed PCBs. This is expensive and wasteful. Does the SIPLACE team offer an option to continue with the SMT production without any major problems after a power outage? SIPLACE Auto Recovery comes in handy in areas with frequent power outages or other interruptions. With this utility, the machines continue exactly where they left off when the production restarts. The line does not have to be cleared, and each PCB will be fully populated. In some cases, the machine may request a manual confirmation whether or not a component has already been placed. To make this process as easy as possible, the machine places the component camera over each position in question and asks the operator to confirm the presence of a component or request a placement. Matsunichi is also delighted about the solution for this challenge. With the Alternative Track function, you can set up alternative components for tracks that are about to run empty without having to define these in advance in SIPLACE Pro. You can then set up the spare component supply on any available track, and the system automatically switches over to this track when the primary track runs empty. This reduces and in some cases completely eliminates the need for splicing. Zhang Jianhua SMT Manager Matsunichi Digital Development Co., Ltd. Shenzhen, China Small lot sizes, rapid workflows, lots of different products, and all of it at top quality and on time these are the challenges Pepperl+Fuchs and many of my other customers in Southeast Asia are facing today. I am glad that we can resolve almost any challenge quickly and cooperatively with our SIPLACE platform, SIPLACE software and SIPLACE services. Terence Wong, SIPLACE Account Management Singapore 29

30 Controlled data management with SIPLACE EDM Willi Keckstein Project Manager Gigaset Communications GmbH Bocholt, Germany Mr. Keckstein, what are your requirements regarding placement program modifications? What improvements would you like to see? One special feature of SIPLACE EDM: Any changes and adjustments made on the line are automatically stored as a new version of the placement program. The system then notifies the programmer about these changes via . The programmer can check the modifications in the EDM Clearing Pool and decide whether or not to replicate the changes in the master data. If the programmer confirms the changes, they are automatically transmitted to all lines without any additional effort on his or her part. We place roughly 4.2 billion components per year. With this kind of volume, we naturally have to make occasional programming changes because package data has changed. When we do this, the changes apply only to the specific line, which means that we must replicate them on all the other lines which manufacture the same product. This means that we have to make the same change multiple times. Can the SIPLACE team forward the placement data to other lines in 30 seconds or less? Zhang Jianhua SMT Manager Matsunichi Digital Development Co., Ltd. Shenzhen, China Super-easy machine operation with the SIPLACE Smart GUI SIPLACE EDM provides a proven solution for managing production data and placement programs across multiple lines. It allows you to administer placement programs in a central location, from which they are then transmitted to the lines. Ulrich Niklas Chief Technology Officer Zollner Elektronik AG Zandt, Germany Manufacturing involves technical as well as personnel-related challenges. Occasionally The analysts rightly called the constellation of SIPLACE and ASM Pacific Technology as a golden deal. Together with ASMPT and our customers all over the world, we have already made good progress towards our goal of becoming the Number One in electronics production. 30 Mike Möhlheinrich, SIPLACE CFO

31 Using alternative components without additional program downloads with SIPLACE Alternative Components Lin Xinyong SMT Supervisor Konka Electronics Co., Ltd. Dongguan, China Sometimes we unexpectedly get the same component from a different manufacturer and with a different shape. This means that I have to create a new version of the placement program and download it to the line again. All this work takes a lot of time. Does the SIPLACE team offer a way of using alternative components without having to download a new version of the program? With SIPLACE Alternative Components, you can define alternative component descriptions for each primary component in the placement program. Once an alternative has been specified, both variants can even be spliced to each other. The system recognizes and accepts the alternative component immediately, and the placement process continues. This not only reduces the number of line stops, but avoids frequent placement program changes and related sources of errors. With SIPLACE Alternative Components, component bottlenecks and ad-hoc second sourcing become much less of a nightmare. you need additional staff for an SMT line an operator may have become ill, or customers are placing unusually large orders. In such cases, we first try to fill the gap with untrained personnel. The question is therefore: How can I deploy these people quickly and efficiently at a placement machine? Can the SIPLACE team instruct even an inexperienced worker to fix a tape break within three minutes or less? Untrained personnel is never the best solution, but the SIPLACE Smart GUI provides support even for untrained temps. It localizes and displays the source of the trouble. In over 90 percent of malfunctions, users see a clear analysis of the error. The system then uses animated instructions to show how to fix the error. This eliminates the need for specialists in most cases even when temps are working on the line. SIPLACE continues in the tradition of German engineering with its enthusiasm for technology and its unconditional pursuit of technical perfection. At the same time we are learning from our colleagues at ASM how to face all challenges in a highly targetoriented and efficient manner. Josef Ernst, Head of SIPLACE R&D 31